Special mention: Belgotex Floors — Zero waste and massively improved efficiencies

Leading the way in best manufacturing practice, Belgotex Carpets have revolutionised their 100 square metre industrial plant outside Pietermaritzburg and invested heavily in sustainable processes.

As a result the factory has been awarded six stars in South Africa’s first custom Green Star SA Existing Building Performance rating, for an industrial facility from the Green Building Council of South Africa.

The six-star certification recognises “World Leadership” for sustainability practices in all aspects of their plant and carpet manufacturing operations. The rating is based on adherence to sustainability criteria that include management, energy, water, transport, materials, land use, ecology and emissions.

As well as meeting all the criteria, Belgotex is affecting real change throughout their value chain. For instance, they have adopted a drymanufacturing process that is a complete switch to solution-dyed ranges, resulting in a 100% reduction in water consumption, as well as reductions in chemical and energy inputs.

Additionally, they acquired a R5-million recycling machine that allows them to recycle waste fibre and yarn back into their production line. This effectively reduces waste rates from the carpet production process to zero. It also offers up to 20% energy savings, resulting in lower production costs and reduced CO2 emissions.

Further investment includes the installation of a R17-million photovoltaic (PV) solar power plant, energy-efficient LED lights and automatic motion sensors, and extensive plant upgrades to more energy-efficient equipment.

“Our main goal is to operate a sustainable factory wherever economically and environmentally feasible,” explains Kevin Walsh, chief operations officer at Belgotex Floors.

“For us, it makes good business sense. It improves operational efficiencies, product development and social upliftment, and positions us as industry leaders.”